Wacker Neuson ET42 EZ50 ET58 System Manual - PDF DOWNLOAD

Wacker Neuson ET42 / EZ50 / ET58 System Manual Version 1.0

Inhalt Type of excavator E19-01 / E19-02 / E19-03 Version 1.0

August 2020

General Hydraulic / Electric / Electronic

ET42 / EZ50 / ET58 System Manual V1.0 Reference (apr02)

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General The system manual describes the function of the Wacekr Neuson ET42 / EZ50 / ET58 system and components. It is an WN internal document for trainers and employees.

The system manual is offered additional to the service manual ET42 / EZ50 / ET58.

Additional documentation EN:  Operator manual  Spare parts list  Service manual

ET42 / EZ50 / ET58 System Manual V1.0 Reference (apr02)

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System Manual ET42 / EZ50 / ET58  GENERAL

General  Content

Content

GENERAL 

Content



Location

HYDRAULIC CIRCUITS AND COMPONENTS 

Circuit working hydraulic pump / Main block



Working pump T003



Main control block C001



Oil cooler L040



Oli tank L042



OPTION: Thermomanagement valve C048

ET42 / EZ50 / ET58 System Manual V1.0 Reference (apr02)

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Content

HYDRAULIC CIRCUITS AND COMPONENTS 

Circuit Pilot Oil



Pilot oil supply unit C006



Joystick left / right C007 / C008



Traveling valve C009



Pilot valve (pedal actuation) C010



OPTION: Proportional valve C018



Circuit working hydraulic arm function



Load holding function L001



OPTION Hose burst valve L062



OPTION Changeover valve HP C032 (VDS)



OPTION Pressure relief valve AUX C040

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Content

HYDRAULIC CIRCUITS AND COMPONENTS 

Circuit working hydraulic Drive



Hydraulic motor T011



Circuit working hydraulic Slewing



Gear motor T015

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Content

ELEKTRIC 

Wiring harness overview



Main harness FRW1



Increased pump output solenoid valve Y011



Sensor speed control B067



Switch driving signal S233



Joystick right C008 / Joystick links C007



Dozer blade Joystick C009



Wiring harness Cabin Display CBW2



Wiring harness Motor WN ENW1

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Content

ELEKTRONIC 

Main Vehicle Control Unit MVCU N004



Engine Control Unit N005



JogDial N023



3,5 inch / 7 inch Display P014



Connector diagnostics XE04 / XE03

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General  Location

Side view

Location

Cab air filter Fuse box

Engine hood

Base plate Left maintenance cover

Left side panel

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Side view

Location

Radiator cover

Engine hood

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Bottom view

Location Underbody maintanace access

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System Manual ET42 / EZ50 / ET58  HYDRAULIC

HYDRAULIC CIRCUITS AND COMPONENTS  Circuit working hydraulic pump / Main block

Functional description Circuit working When the combustion engine is running, the working pump T003 sucks the oil from the tank L042 via the suction connection The oil is conveyed to the inlet element of main control block C001 via connection P on the working pump. The oil flows through the tank channel of the main control block and flows to the collecting unit L046 via the tank connections T1 and T2.

Part of the oil flows from the collecting unit L046 via the oil cooler L040 and part via the hammer return valve C036 via the return filter Q012 back into the tank.

The stand-by pressure is generated via the pressure compensator in the inlet element and the back pressure in the tank line.

The pilot oil supply unit C006 at the PPS connection is also supplied via the inlet element.

In addition, the thermal management valve C048 is supplied via the PPS pilot oil connection on the main control block C001.

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Circuit working Tswing (E19-01) Tswing (E19-02/03)

T1 T2

C039

L046 C001

B067

L060

L040 C048

Q001

C039 S005

Y11 Q012 Y187

T001 Q013

L042

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HYDRAULIC CIRCUITS AND COMPONENTS  Working pump T003

Functional description Working pump T003 If the engine doesn‘t run, the spring in the spring chamber of the setting piston (left chamber, piston rod side) acts the captive washer of the variable displacement pump into position Qmax (max. volume flow).

If the engine starts to turn, the pump starts to deliver. The backpressure in the P-line acts against the Delta-P setting on the flow compensator. If the pressure in the P-line is higher than the setting of the flow compensator, this one opens to the setting piston and the pressure in the P-line slews the captive washer of the pump back to Qmin.

If a function is acted on the main control valve, the LS-Signal is sent via the LS connection to the flow compensator. This signal closes the flow compensator against the pressure in the P-line and the captive washer of the pump slews direction Qmax.

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Connections Working pump T003 The working pump T003 is mountd directly at the engine.

X

C001_Main control block

FR

The working pump has following connections and main components:

T001 _Diesel engine

DR

•

S

suction line

•

B

pressure line

T003_Arbeitspumpe

LR

Via the connection B the main control block is supplied with oil •

L042_Hydraulic oil tank

Reference (apr02)

LS signal

The LS signal of the consumer is reported from the main control block via the connection X to the working pump

Q013_suction filter in the tank

ET42 / EZ50 / ET58 System Manual V1.0

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Compensator working Pump T003 DR …

Pressure compensator

X

C001_Main control block

The pressure compensator is an additional pressure limiter to the main pressure relieve valve on the main control valve. The setting is higher than the main pressure relieve valve.

FR

DR

T001 _Diesel engine

FR …

T003_Arbeitspumpe

LR

According the pressure difference Delta-P, set on the flow compensator, the pump controls the volume flow against the LS-Signal from the main control valve.

Q013_suction filter in the tank

L042_Hydraulic oil tank ET42 / EZ50 / ET58 System Manual V1.0 Reference (apr02)

Flow compensator

22

Compensator working Pump T003 LR …

Power compensator

X

C001_Main control block

To prevent the combustion engine from being overloaded, the power compensator regulates the volume flow of the working pump. The power compensator of this excavator series is electronically controlled via the Main Vehicle Control Unit N004.

FR

T001 _Diesel engine

DR

Variables for this regulation are, e.g.: T003_Arbeitspumpe

LR

Q013_suction filter in the tank

• Selected rpm engine speed and the corresponding maximum torque of the combustion engine • Pressure in the system measured by sensor B067 in the LS line A mechanical overriding of the power compensator is not possible due to the electronic control via the solenoid valve Y011

L042_Hydraulic oil tank ET42 / EZ50 / ET58 System Manual V1.0 Reference (apr02)

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Working pump T003 4

3 2 1

5

6

7

1

Spring

2

Pull back plate

3

Setting piston

4

Compensator block

5

High pressure side

6

Control plate

7

Suction side

8

Cylinder

9

Piston

10 Sliding shoe 11 Captive washer 11

10

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8

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Connections / components working pump T003 1

LR

The working pump T003 has the following connections / components

2

S

B

Pressure flange (connection P1)

S

Suction connection

1

Air bleeding screw

2

Drive shaft

DR Pressure compensator FR Flow compensator

X FR

DR

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B

25

LR

Power compensator

X

LS signal

HYDRAULIC CIRCUITS AND COMPONENTS  Main control block C001

General information main control block C001 The main control block is installed under the cabin in the area of the entrance.

The main control block is arranged differently depending on the options selected •

Basic version with 9 sections

•

10 sections for option angle blade and floating position or AUX2 (AUX3)

•

10 sections for option angle blade and floating position

This variant excludes AUX2 (AUX3) and the overload system. Pressure limiters (secondary) are installed as standard •

10 sections for option AUX2 (AUX3)

This variant excludes angle blade and floating position. No pressure limiters (secondary) are installed as standard

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Section main control block C001 The main control block C001 is divided into the following sections:

Inlet section OPTION angle blade / AUX2 Slewing Drive (right) Drive (left) Boomc ylinder Stick cylinder Bucket cylinder Dozer blade (OPTION floating position) Swivel cylinder AUX1 End element

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Connections / components main control block C001 The main control block C001 has the following connections / components: PPS

T1

A / B Pressure connection MRV

Pb0

P

PL

PBI

Pa/Pb Hydraulic operation

PLS Pa0

P

Connection pump

A1

Pa1

T1

Connection Tank

B2

A2

Pa2

T2

An Connection schluss Tank

B3

A3

Pa3

PPS

Connection Pilot oil supply unit Connection LS signal

B0

A0

Pb1

B1

Pb2 Pb3

PL

Pb4

SRV

B4

A4

SRV

Pa4

PLS

Pb5

SRV

B5

A5

SRV

Pa5

MRV Main pressure relief valve

Pb6

SRV

B6

A6

SRV

Pa6

PBI

Pb7

SRV

B7

A7

CV

Pa7

PBW Pressure balanceworking element

CV

Pa8

SRV Pressure limiters (secondary)

Pa9

CV

Check valve

PL

Plug

Pb8

PL

B8

A8

Pb9

PL

B9

A9

PL

T2 PBW ET42 / EZ50 / ET58 System Manual V1.0 Reference (apr02)

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Pressure balance inlet element

Functional description main valve block C001 The main control block C001 is supplied with oil via port P and therefore oil flow through only from one direction. In order to enable optimal routing of the hydraulic hoses, the arrangement of the working elements was chosen in this form.

Depending on the requested amount of oil, defined by the position of the control spool, the working pump T003 supplies oil.

If no function is activated, Qmin of the pump is supplied to the tank via the inlet element.

By activating a function, the oil is delivered to the consumer via the spool.

With multiple actuation, a load-independent distribution of the amount of oil is guaranteed.

Pressure limitation is done primarily via the main pressure relief valve in the inlet element and individual sections can contain secondary pressure protection

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Section inlet element function A… Inlet element pressure balance The working pump delivers oil from the hydraulic tank to the main control valve connection P In the inlet element the maximum working pressure is limited by the main pressure relief valve.

A

If no function is operated, the oil flows over the pressure balance into tank. The force of the spring of the inlet pressure balance defines the stand by pressure.

By operating a function, the LS canal (purple) also gets pressure from the load. This pressure is acting additionally on the spring side of the pressure balance and closed the connection to tank. The oil from the working pump flows to the working section

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Section inlet element function B… Flow control valve LS cannel Oil flow is permanently possible over the flow control valve into tank The leakage enables the LS channel to be discharged (reduction of pressure peaks) The leakage quantity is insignificant during working

B

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Section inlet element connections PLS B

LS MRV

T1 PBI PBI

PPS

PLS

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P

Connection Pumpe

T1

Connection Tank

PPS

Connection pilot oil supply unit

PLS

Connection Ls signal

MRV

Main pressure relief valve

PBI

Pressure balance inlet element

B

Flow control valve LS cannel

Section inlet element connections PLS P

LS

LS

B

MRV

T1

T PBI

P

Connection Pumpe

MRV

Main pressure relief valve

T1

Connection Tank

PBI

Pressure balance inlet element

PPS

Connection pilot oil supply unit

B

Flow control valve LS cannel

PLS

Connection LS signal

LS

Load Sensing cannel

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Section arm cylinder function

P

The function of the arm cylinder section is explained below as an example: By proportional activation of the function boom cylinder lifting via the pilot oil pressure (Pa4) the spool (1) is operated. (grey area).

2

The volume flow of the pump is sent via the spool (flow regulating function) to the working element pressure balance (2).

1

If only one function is activated, no relevant pressure is acting on the LS side of the pressure balance (2).

Thereby the pressure balance is acted completely. (2) (grey area).

LS

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Section arm cylinder function Via the pressure balance (2) (grey area) the oil flow is sent back to the spool (1) and further to the boom cylinder P 2

Via the LS signal the inlet element pressure balance will be closed and the pump delivers the requested volume flow

1

LS

ET42 / EZ50 / ET58 System Manual V1.0 Reference (apr02)

At the same time the LS cannel and the LS side of the working element pressure balance is charged with the pressure of the load. According to the equation on both sides of the pressure balance no control mode is done by the pressure balance. As recently as the amount of oil flow changes over the spool, the pressure balance try to equate the pressure rate again

The flow of the pump is regulated over the pressure in the LS canal and the position of the flow restrictor of the spool

36

LUDV – Load Independent Flow Distribution (Function) 200 bar

150 bar

Situation: Operating more than one function Function 1 works with 200 bar (higher) pressure from the load. Function 2 works with 150 bar (lower) pressure from the load.

P B

A

1

2

200 bar

LS

ET42 / EZ50 / ET58 System Manual V1.0 Reference (apr02)

Due to the operating with pilot pressure the requested volume flow according the position of the spool is sent to the working element pressure balance. The pressure balance acts a downstream flow regulator and controls the volume flow over the spool to the consumer by balancing the pressure difference between P and LS; delivers the requested volume flow even differential pressure levels in the sections.

Even by changing pressure levels in the sections, the volume flow stays constant, if the position of the spool is kept. (Differs to the flow regulator control properties, where the volume flow is affected by changing pressure levels) 37

LUDV – Load Independent Flow Distribution (undersaturation) 200 bar

Situation: Operating more than one function

150 bar

The limit of this system is achieved, when the requested volume flow of the users is higher than the maximum volume flow of the pump. (many functions used at once). This condition is called undersaturation.

P B

A

1

The working element pressure balances split the max. volume flow equal according the different pressure levels P to LS in the sections. All functions can be used further „load independent“, just with less speed. This can be guaranteed, as long as the DeltaP setting on the flow compensator can be kept. If P=LS, the system works undefined or the functions stop.

2

200 bar

LS

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LUDV – Load Independent Flow Distribution (summary) 200 bar

150 bar

Situation: Operating one function Control of the volume flow to the user via spool and working element pressure balance. The pump delivers the requested volume flow.

P

Situation: Operating more than one function

B

A

Control of the volume flow to the user via spool and working element pressure balance according pressure difference P to LS. The pump delivers the requested volume flow.

Situation: Undersaturation 1

Control of the volume flow to the user via spool and working element pressure balance according pressure difference P to LS as long as DeltaP setting can be kept. (flow sharing).

2

200 bar

LS

ET42 / EZ50 / ET58 System Manual V1.0 Reference (apr02)

Afterwards functionality undefined or the functions stop

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Section boom cylinder connections LS

A4

B4

The section boom cylinder has the following hydrauic connections: A4 Connection Boom cylinder pistenrod side B4 Connection Boom cylinder pisten side Pa4 Operation pilot oil A side Pb4 Operation pilot oil B side

T Pa4

P

Pb4

LS LS cannel

P

P

Pump cannel

T Tank cannel

LS T ET42 / EZ50 / ET58 System Manual V1.0 Reference (apr02)

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Section boom cylinder components 3

4

4

The section boom cylinder has the following components:

1 2

3

4 2

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1

Housing

2

Spool

3

Working element pressure balance

4

Pressure limiters (secondary)

Main components detail 1

1

The following variants for secondary pressure limitation are available: - Section without pressure limitation (no drill hole in the housing) - Section with pressure limitation 1) Plug for additional assembly

1

2) Check valve without pressure limitation 3) Pressure limiters (secondary) Pressure limiters (secondary) (1) are settable

1

Presetting: grey (Std) 265 bzw. 285 bar red (PT) 200 bar black (hydr. thumb) 170 bar

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Section stick cylinder Pistenrod

Rod

The section stick cylinder according to the connections and the main components is identical to the boom cylinder section.

A regeneration function is integrated in the spool to increase the retraction movement of the stick cylinder when there is no load on. The oil of the piston rod side is transported to the piston side

3

4 2 Detail spool

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Section dozer blade (OPTION floating position) Floating position

Spacer block

Spacer block

3

4 2 Detail spool

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The section stick cylinder according to the connections and the main components is identical to the boom cylinder section.

The function of the floating position is integrated in thee spool. An additional position enables the pressure equalization of the A & B side in the tank

HYDRAULIC CIRCUITS AND COMPONENTS  Oil cooler L040

Oil cooler L040 The cooling package is mounted at the oil tank The cooling package containes 2 cooler: •

Oil cooler

•

water cooler

The pressing system will e.g. for the valves (under the cabin) an optimal thermal balance is guaranteed. In order to achieve good cooling performance even despite air over the engine compartment, the radiator was dimensioned large.

L060

The oil cooler L040 is flown through once from bottom to top.

The check valve L060 is installed at the inlet of the cooler. This valve generates a 2 bar preload as protection against cavitation.

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HYDRAULIC CIRCUITS AND COMPONENTS  Oil tank L042

Oil tank L042

The oil tank is mounted behind the cooler package 1. Return filter Q012 2. Dust indication S005 (switching value 2 bar) 3. Breath filter Q001 4. Suction filter Q013 5. Connection from oil cooler L040 6. Connection from hammer return valve C039 7. Connection suction working pump T003

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Oil tank L042

10

6

3 1

1. Return filter Q012

5

2. Dust indication S005 (switching value 2 bar) 3. Breath filter Q001 4. Suction filter Q013 5. Connection from oil coller L040 6. Connection from hammer return valve C039 2

7. Connection suction working pump T003 8. Connection tank operation pilot oil 9. Oil drain plug 10. Cooler package

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8 49

HYDRAULIC CIRCUITS AND COMPONENTS  OPTION Thermomanagement valve C048

OPTION Thermomanagement valve C048 The Thermomanagement valve is installed below the battery

Y187 1

P

Pressure connection main control block

LS

Pressure connection working pump

T

Tank connection

P

1

Pressure cartrige

LS

Y187 Connector thermomanagement valve

T

The purpose of the thermomanagement valve is to load the engine in cold conditions so that the engine and furtheron the exhaust aftertreatment system reach operating temperature earlier The built-in 2/2-way valve Y187 is electrically controlled and applies the working pressure to the load pressure line. The built-in pressure relief valve limits the working pressure to 90 bar ET42 / EZ50 / ET58 System Manual V1.0 Reference (apr02)

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OPTION Thermomanagement valve C048 Y187 = 12V:

Y187 1

•

after 60 seconds engine started or after 180 seconds engine is runnung B067 < 10 mA the cooling water temperature is < 68°C

-

T

P

Y187 = 0V: LS

-

B067 > 10 mA the cooling water temperature is > 75°C

RPM speed reduction When thermomanagement valve is activated, the rpm speed increases to the initial set rpm speed.

After deactivation, the rpm speed drops again Correlation with Auto-Stopp

ET42 / EZ50 / ET58 System Manual V1.0 Reference (apr02)

The period of time of the Auto-Stop function must be longer than the activation of the thermomanagement valve 52

HYDRAULIC CIRCUITS AND COMPONENTS  Circuit Pilot Oil

Functional description circuit pilot oil The pilot control circuit is supplied via the inlet element of the main control block C001 at connection PPS via connection P on pilot oil supply unit C006.

After Y013 is energized, the oil flows internally to the solenoid valves for AUX1 and dozer blade and then directly to the pilot oil connection on the control block and externally via the Pdis connection to the distributor L048.

From there via the respective pilot valves to the pilot oil connections on the control block.

If Y013 is de-energized, the oil flows back into the tank via the tank connection.

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Circuit pilot oil Main control block C001

C006

Distributor

C001

L048 T003

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HYDRAULIC CIRCUITS AND COMPONENTS  Pilot oil supply unit C006

Pilot oil supply unit C006

The pilot oil supply unit C006 is installed under the cab between the main control block C001 and the engine.

P

Pressure connection

The valve is supplied with oil via the main control block C001 at port PT T

Tank connection

The tank is relieved via port T PV Test port connection L068

PR Speed range selection

P3 Connection pilot oil to main control block AUX1 (right)

By energized the solenoid valve Y039 is, a higher gear is selected

P4 Connection pilot oil to main control block AUX1 (left)

BV Unlock pilot oil supply The switch S029 is closed by putting the armrest in working position. This energizes the solenoid valve Y013 and pilot oil pressure is applied to the pilot valves.

P1 Connection pilot oil to main control block dozer blade up P2

Connection pilot oil to main control block dozer blade down

Acc Connection accumulator L018

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The pilot oil supply unit C006 has the following hydraulic connections and main components:

Pilot oil supply unit C006

Connections : P Pressure connection T Tank connection Acc Connection accumulator L018 P4 Connection Pa9 main control block C001 P3 Connection Pb9 main control block C001 Bauteile:

P2 Connection Pa7 main control block C001

Y034 Additional control circuit solenoid valve

P1 Connection Pb7 main control block C001

Y033 S Additional control circuit solenoid valve

PV Test port connection L068

Y145 Stabilizer blade solenoid valve 2

BV Connection Distributor pilot oil 6

Y144 Stabilizer blade solenoid valve 1

PR Connection swivel joint 1A

Y013 Joystick OFF pilot control safety valve Y039 2nd speed range solenoid valve DBV Pressure limiting valve L018 Pilot control pressure accumulator 1 ET42 / EZ50 / ET58 System Manual V1.0 Reference (apr02)

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Pilot oil supply unit C006

PPS

P

PP

Pdis

Pb7

Pa7

Pb9

Pa9

PR

BV

P1

P2

P3

P4

T

PV

C006 Pilot oil supply unit

L068

L018

DBV

Y039

ET42 / EZ50 / ET58 System Manual V1.0 Reference (apr02)

Y013

59

Y144

Y145

Y033 Y034

HYDRAULIC CIRCUITS AND COMPONENTS  Joystick left / right C007 / C008

Joystick C008 Pb4

Pa4

1

Pb6

3

2

1

2 4

3

P 2

T

1

Distributor Pilot oil supply unit C006 3

ET42 / EZ50 / ET58 System Manual V1.0 Reference (apr02)

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61

Pa4

4

Joystick C007 Pb5

Pa5

1

Pb1

3

2

1

2 4

3

P 2

T

1

Distributor Pilot oil supply unit C006 3

ET42 / EZ50 / ET58 System Manual V1.0 Reference (apr02)

4

62

Pa1

4

HYDRAULIC CIRCUITS AND COMPONENTS  Traveling valve C009

Traveling valve C009 Pa3

Pb3

Pa2

P T 2

3

4 1

The hydraulic decoupling of the damping elements enables viscosity-independent driving The reversing signal is reported electrically to the MVCU via an internally installed sensor (Plug S233)

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Distributor Pilot oil supply unit C006

Pb2

HYDRAULIC CIRCUITS AND COMPONENTS  Pilot valve (pedal actuation) C010

Pilot valve (pedal actuation) C010 Pa8

Pb8

P T

Distributor 2

1

Pilot oil supply unit C006 ET42 / EZ50 / ET58 System Manual V1.0 Reference (apr02)

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HYDRAULIC CIRCUITS AND COMPONENTS  OPTION: Proportional valve C018

OPTION: Proportional valve C018 Magnet resistance R20 = 5,2 Ohm I max = 1500 mA Pmax = 50 bar IP65, DC, 12V

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Y080

Magnet 10.1 AUX II right

Y081

Magnet 10.2 AUX II left

OPTION: Proportional valve C018 Magnet resistance R20 = 5,2 Ohm I max = 1500 mA Pmax = 50 bar IP65, DC, 12V

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Y122

Magnet 10.1 Angle blade

Y123

Magnet 10.2 Angle blade

HYDRAULIC CIRCUITS AND COMPONENTS  Circuit working hydraulic arm function

Function description working hydraulic arm function If pilot oil pressure acts on port Pa4 or Pb4 via pilot valve C008 joystick right, the spool in the working section moves and the oil flows via the working element pressure balance from the pressure channel to pressure port A4 or B4.

In the standard version the load holding valve L001 is installed between the main control block C001 and the boom cylinder Z001 It is not mounted at the OPTION overload system and is replaced by the hose burst valve L062

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Working hydraulic arm function

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HYDRAULIC CIRCUITS AND COMPONENTS  Load holding function L001

The loadholding valve L001 is installed under the footwell of the cabin.

Load holding valve L001 function X A1

A

Pressure connection main control block

A1

Pressure connection Boom cylinder

T

Tank connection

X

Pilot signal port

CT1 Pressure cartridge As soon as pilot pressure is applied to the Pdis connection of the distributor L048 by putting armrest in the working position, the load-holding valve L001 is released in both directions, lifting and lowering, via connection PX.

A CT1 T

Without pilot pressure on PX, the load holding function of this valve is activated

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HYDRAULIC CIRCUITS AND COMPONENTS  OPTION: Hose burst valve L062

OPTION: Hose burst valve L062 boom cylinder The hose burst valves are located directly on the relevant cylinder Hose burst valves block the oil drain if there is a loss of pressure due to hose brake

1

A

Pressure connection main control block

A1

Connection pressure switch B066

T

Tank

X

Connection Pilot oil line Pb4

CT1 Valve cartridge 1 CT2 Valve cartridge 2

Only authorized persons are allowed to adjust the setting Main control block C001 ET42 / EZ50 / ET58 System Manual V1.0 Reference (apr02)

Pressure limiters (secondary) 76

OPTION: Hose burst valve L062 boom cylinder Boom down CT1

If the function boom down is operated, the main spool (C001) and valve CT1 (by pilot port Pb1 and port X) is opened at the same time

A1

CT2

Pressure limiting valve CT2 X

T

Valve CT2 opens if the setting pressure is reached. The pressure closes the check valve 1 and pilots CT1

A

The oil can flow direct from A1 to A and opens the secondary pressure limiting valve (main valve block C001) to tank

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OPTION: Hose burst valve L062 stick cylinder The hose burst valves are located directly on the relevant cylinder

CT1

Hose burst valves block the oil drain if there is a loss of pressure due to hose brake A

Pressure connection main control block

A1

Connection pressure switch B066

T

Tank

X

Connection Pilot oil line Pb4

CT1 Valve cartridge 1

CT2

CT2 Valve cartridge 2

Only authorized persons are allowed to adjust the setting Main control block C001

Pressure limiters (secondary)

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OPTION: Hose burst valve L062 stick cylinder Stick down If the function Stick down is operated, the main spool (C001) and valve CT1 (by pilot port Pb1 and port X) is opened at the same time

CT1

CT2

Pressure limiting valve CT2 X

T

Valve CT2 opens if the setting pressure is reached. The pressure closes the check valve 1 and pilots CT1

A

The oil can flow direct from A1 to A and opens the secondary pressure limiting valve (main valve block C001) to tank

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HYDRAULIC CIRCUITS AND COMPONENTS  OPTION: Changeover valve HP C032 (VDS)

OPTION: Changeover valve HP C032 (VDS) The changeover valve HD C032 is located in the area of the gear motor / swivel joint

D C

Y018 B

T A

A

Connection B6

B

Connection A6

C

Connenction Z003 (bucket piston rod side)

D

Connection Z003 (bucket piston side)

E

Connenction 10A swivel joint

F

Connenction 9A swivel joint

T

Tank connenction

F E

Y018 Solinoid valve (upper carriage tilt)

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By actuating switch S037, the solinoid valve (upper carriage tilt) Y018 is energized via the MVCU. Thus, the oil is diverted from the bucket cylinder to the two VDS cylinders

OPTION: Changeover valve HP C032 (VDS) Signals at the control units for the function VDS on N004 Incoming signal PIN BMK Component 55 S037 connector button tilt switch spoon 57

S037

Signal 12V

connector button tilt switch spoon

0V

N004 Outgoing signal PIN BMK Component 39 Y018 Solinoid valve (upper carriage tilt)

Signal 12V CAN-Bus Signal to display P014

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HYDRAULIC CIRCUITS AND COMPONENTS  OPTION: Pressure relief valve AUX C040

OPTION: Pressure relief valve AUX C040 P4

P3

P2

P1

The pressure release valve AUX C040 is located behind the main control block C001

T

Y106

P1

Connection to hose from A9

P2

Connection to hose from B9

P3

Connection to hose from B0

P4

Connection to hose from A0

T

Tank connection

Y106 Solenoid valve pressure relief Pressing switch S148 Switch pressure relief energizes the solenoid valve pressure relief Y106. This relieves the pressure of AUX in the tank and thus enables the pressure-free coupling of attachments during operation

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OPTION: Pressure relief valve AUX C040 Signals at the control units for the function pressure relief on N004 Incoming signal PIN BMK Component 47 S148 Switch pressure relief 63

S148

Signal 12V

Switch pressure relief

PIN BMK Component 1 S148 Switch pressure relief

0V

Signal 12V

Vizualisation Display If AUX is activated when the pressure release valve is activated, the following symbol appears on the display

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HYDRAULIC CIRCUITS AND COMPONENTS  Circuit working hydraulic Drive

Function description circuit working hydraulic Drive If pilot oil pressure acts on port Pa2 or Pb2 via traveling valve C009, the spool in the working section moves and the oil flows via the working element pressure balance from the pressure channel to pressure port A2 or B2.

The oil reaches the hydraulic motor via the rotary union L017, connections 3A or 5A

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Circuit working hydraulic Drive

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HYDRAULIC CIRCUITS AND COMPONENTS  Hydraulic motor T011

Hydraulic motor T011 The hydraulic motor T011 is installed in the rear part of the chassis.

A

Pressure connection A

B

Pressure connection B

DR2 Drain oil connection motor

W

PP

Connection 2nd speed range

L

Valve break release

FG

Valve 2. 2nd speed range

W

Shuttle valve

FG

L

DR2

DR1

A

B

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Hydraulic motor T011 Drive, release park break The oil gets to the connections of the hydraulic motor A / B via the swivel joint L017, connections 3a or 5a Via the in internal acted valve 1 the park break is released and the oil flow is possible to the relevant side of the drive motor.

Non acted the park break is closed, because the pilot line is connected via the connection DR to tank

1

DR2

DR1

A

B

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Hydraulic motor T011

DR2 B PP A

DR2

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DR1

A

B

PP

A

Pressure connection A

B

Pressure connection B

DR2

Drain oil connection motor

PP

Connection 2nd speed range

Hydraulic motor T011

W L FG FG L W

DR2

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DR1

A

B

L

Valve break release

FG

Valve 2. 2nd speed range

W

Shuttle valve

PP

Hydraulic motor T011 Drive direction forward: T011 Tunring direction anti clockwise (connection A3 main control valve) E

T012 Tunring direction clockwise (connection A4 main control valve)

L

A

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E

Filler screw

L

Level plug

A

Drain screw

Speed range selection

Hydraulic motor T011

By actuating 1/2 speed switch S021, the 2nd speed range solenoid valve Y039 is energized via the MVCU Drive slow (1. speed range) The solenoid Y039 is not activated and the pilot is sent to tank.

2

Drive fast (2. speed range)

DR2

DR1 A

B

PP

If Y039 is energized, the pilot pressure at port PR is routed via port 1A of rotary distributor L017 to port PP on traction motor T011.

L017

This causes a slewing back of the motor in direction Qmin and an increasing of the driving speed.

DBV

If the pressure is rising (e.g. uphill drive) the valve autonomous switches back into 1st gear. (Auto kick down)

C006 Pilot oil supply unitt

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Speed range selection Signals at the control units for the function speed range selection 2. speed range N004 Incoming signal PIN BMK Component 64 S021 1/2 spped switch

Signal 12V

N004 Outgoing signal PIN BMK Component 73 Y039 2nd speed range solenoid valve

Signal 12V CAN-Bus Signal to display P014

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HYDRAULIC CIRCUITS AND COMPONENTS  Circuit working hydraulic Slewing

Function description circuit working hydraulic Slewing If pilot oil pressure acts on port Pa1 or Pb1 via the pilot control valve C007 joystick left, the spool in the working section moves and the oil flows via the working element pressure balance from the pressure channel to pressure port A1 or B1 As soon as pilot pressure is applied to connection Pdis of distributor L048 by putting armrest in the working position, the holding brake is released via connection PPB

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Circuit working hydraulic Slewing

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HYDRAULIC CIRCUITS AND COMPONENTS  Gear motor T015

Gear motor T015 The gear motor T015 is mounted under the drivers seat

DBV

A

Pressure connection A

B

Pressure connection B

T

Tank connection

DR Drain oil connetion gear motor PP

Connection holding break

DBV

DBV Pressure limiters (secondary) A / B side

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Gear motor T015 Pressure limiters (secondary) The maximum possible working pressure of the slewing motor is limited by the Pressure limiters (secondary) (DBV) DBV

If the pressure reaches the adjusted setting, the valve opens to the low pressure side.

The open- and close motion are damped internal.

DBV

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Gear motor T015

Cavitation protection To avoid cavitation during „cut off“ movement, the missing oil is sucked from the pretension tank line over the ant cavitation valves (1).

1

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Gear motor T015 DBV

A

Pressure connection A

B

Pressure connection B

T

Tank connection

DR

DR

Drain oil connetion gear motor

1

PP

Connection holding break

DBV

Pressure limiters (secondary) A / B side

1

Anti cavitation valve

DBV A

T

PP B

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System Manual ET42 / EZ50 / ET58  ELEKTRIC / ELECTRONIC

ELEKTRIC  Wiring harness overview

Wiring harness overview Following options are differed in the wiring harness: •

CANOPY

•

CABIN

Following wiring harness are used per option FRW1 main harness FRW2 cable Lights Boom FRW4 battery cable Negative FRW5 Negative-cable FRW6 battery cable Plus FRW7 Plus-cable Option FRW3 cable Overload CBW7 cable ignition key standard CB1 Std FR1 Std

Option EN1 Std

ENW1 Wiring harness Motor WN

ET42 / EZ50 / ET58 System Manual V1.0 Reference (apr02)

CBW4 Wiring harness Canopy Display CBW1 Wiring harness Cabin CBW2 Wiring harness Cabin Display CBW3 Cabin Working lights left CBW5 Canopy Lights CBW8 adapter cable Display 7 inch CBW6 Canopy Rotating beacon

107

Wiring harness overview Following wiring harness are described in detail: •

main harness FRW1 (black)

•

Wiring harness Cabin Display CBW2 (green)

•

Wiring harness Motor WN ENW1 (red)

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ELEKTRIC  Main harness FRW1

FRW1… Main harness

Main harness FRW1 4

6

1

XE11 Connection to FRW2 cable Lights Boom

2

XB66 Connection to FRW3 cable Overload

3

XD00 Connection to CBW1 Wiring harness Cabin

4

XD01 Connection to CBW2 Wiring harness Cabin Display

5

E020 Connection to CBW3 cable Cabin Working lights left

6

XS01 Connection to CBW7 cable ignition key standard

7

XM01 Connection to ENW1 Wiring harness Motor WN

8

XM02 Connection to ENW1 Wiring harness Motor WN

9

XM00.EIC Connection to separator Diesel engine

3

9 7 8

1

2 5

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ELEKTRIC  Increased pump output solenoid valve Y011

Increased pump output solenoid valve Y011 Y011… Control power compensator The rotation speed-dependent engine torque (via CAN bus) and the pressure value in the LS line, measured by the Sensor speed control B067, result in different performance characteristics High pressure = small current = small volume flow Low pressure = high current = large volume flow Cable break = no signal = Qmin Y011

Further influencing variables such as engine reaction time or oil temperature are implemented by the electronic control.

A mechanical overwriting of the power regulator is no longer possible

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ELEKTRIC  Sensor speed control B067

Sensor speed control B067 B067… Control power compensator Measurement of the LS pressure for regulating the power compensator on the working pump High pressure = small current = small volume flow Low pressure = high current = large volume flow Cable break = no signal = Qmin B067

B067… Automatic rpm speed control The automatic rpm speed control is also controlled via the LS pressure, switchable via the JogDial N023 and the button on the left joystick Characteristic Power supply 8-16V Output signal 4-20 mA Pressure range 0-400 bar

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ELEKTRIC  Switch driving signal S233

Switch driving signal S233 S233… Switch driving signal The detection of the travel direction and the activation of the warning horn when driving backward is implemented internally in the traveling valve.

S233

ET42 / EZ50 / ET58 System Manual V1.0 Reference (apr02)

A rotation sensor is built into the valve, which detects the position of the traveling pedal

116

ELEKTRIC  Joystick rechts C008 / Joystick links C007

Joystick right C008 / Joystick left C007 The two joysticks are power supplied via the MVCU N004 and the signals from the rocker and the button are read back into the MVC N004

XJ02

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XJ01

118

Joystick right C008 / Joystick left C007

A

B

B074 Rocker Volume flow AUX I Button A Not in use Button B Not in use S055 Button backside Horn

Steuerhebel rechts C008

B041 Rocker (Option) Volume flow AUX II und AUX III A

B

Steuerhebel links C007

ET42 / EZ50 / ET58 System Manual V1.0 Reference (apr02)

S056 Button A Change over AUX II und AUX III S145 Button B Change over rpm speed setting S153 Button backside Hammer

119

ELEKTRIC  Dozer blade Joystick C009

Dozer blade Joystick C009 C009… Dozer blade Joystick S021

XJ03

Depending on the chosen variant (OPTIN dozer blade floating position or pivoting dozer blade), a differentiation is made between 2- or 4-axis dozer blade joystick. The 4-axis dozer blade lever has a latching position in the end position in order to achieve the floating position S021… 1/2 speed switch The speed ragen of the traveling is choosen with the 1/2 speed switch

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ELEKTRIC  Wiring harness Cabin Display CBW2

Wiring harness Cabin Display CBW2 With the plug XD01 the FRW1 main harness is connected with the CBW2 Wiring harness Cabin Display.

The display (3,5 inch) is connected with the plug P014 With the OPTION 7 inch display the CBW8 adapter cable Display 7 inch is used X101

P014 XD01 CBW2

X100 CBW8 adapter cable Display 7 inch Display 7 inch ET42 / EZ50 / ET58 Systemhandbuch V1.0 Reference (apr02)

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Elektrik  Wiring harness Motor WN ENW1

Wiring harness Motor WN ENW1 Via the plug XDM1 and XDM2 the FRW1 main harness is connected with the ENW1 Wiring harness Motor WN ENW1

the ENW1 Wiring harness Motor WN forms the connection to Perkins with the connector XM00.EIC separator Diesel engine on the main wiring harness FRW1

XDM1

XDM2

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ELEKTRONIC  Main Vehicle Control Unit MVCU N004

Main Vehicle Control Unit MVCU N004 N005

N004

Fuse box

XE04

XE03

Maintenance access fuse box Dismounting coverage of the maintenance access fuse box leads to the control units N004, N005, the fuse box and the two diagnostic plugs XE04 and XE03

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Main Vehicle Control Unit MVCU N004

N004… Main Vehicle Control Unit The upper of the two control units is responsible for the electronic control of the excavator This MVCU has 2 plugs: N04.1

ET42 / EZ50 / ET58 System Manual V1.0 Reference (apr02)

N04.2

128

N04.1

Connector 1

N04.2

Connector 2

ELEKTRONIC  Engine Control Unit N005

Engine Control Unit N005 N005… ECU The lower of the two control units controls the Perkins engine. The signals from the control unit are routed to connector XM00.EIC via the main wiring harness FRW1 and processed via connector T1.EIC on the engine side.

N5.J1

Additionally, motor-relevant signals are processed via ENW1 Wiring harness Motor WN.

N5.J2

Also information are exchanged between the two control units via CAN bus This ECU has 2 plugs:

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N5.J1

Connector ECM J1

N5.J2

Connector ECM J2

ELEKTRONIC  JogDial N023

JogDial N023

N023… JogDial The prm speed is set using the rotary knob on the JogDial.

Detailed information on the setting options on the JogDial can be found in the operation manual

N023

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ELEKTRONIC  3,5 inch / 7 inch Display P014

3,5 inch / 7 inch Display P014

N014… Display One of the two terminating resistors of the vehicle CAN bus is integrated in the display

Display 7 inch X101

P014 X100

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ELEKTRONIC  Connector diagnostics XE04 / XE03

Connector diagnostics XE04 / XE03 XE04

XE03

Maintenance access fuse box Next to the fuse box the diagnosic plugs XE04 und XE03 are located XE04 diagnosic plug vehicle CAN-Bus XE03 diagnosic plug engine CAN-Bus

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Connector diagnostics XE04 / XE03 XE04… OBD2 diagnosic plug CAN 0 Connector pin assignment:

XE04

1

Ignition plus 12V15

4

GND

12

CAN Low

13

CAN High

16

Permanent plus 12V30

Terminating resistors: R813 behind N04.2 (in cable loom connector N04.2) P014 integrated in the display

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Connector diagnostics XE04 / XE03 XE03… diagnosic plug Perkins CAN 1 Connector pin assignment: A

Ignition plus 12V15

B

GND

F

CAN Low

G

CAN High

XE03

Terminating resistors: R812 behind N5.J1 (in cable loom connector N5.J1) N004 integrated in MVCU There are 2 more terminating resistors (Perkins) installed: R810 behind N5.J2 (in cable loom connector N5.J2) R811 In FRW1 at XM00.ECI These two terminating resistors are only used for internal Perkins diagnosis (CAN-C) ET42 / EZ50 / ET58 System Manual V1.0 Reference (apr02)

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